US11027517B2 - Decorative laminates including thermoplastic ink layers and related methods - Google Patents

Abstract

Decorative laminates including thermoplastic ink layers and related methods are disclosed. An example apparatus includes a reinforcing layer to provide a rigidity to a decorative laminate, thermoplastic ink applied to the reinforcing layer to form a decorative pattern of the decorative laminate, and a film layer coupled to the thermoplastic ink to form the decorative laminate. The film layer is to preserve the decorative pattern. The thermoplastic ink is solidified when the film layer is coupled to the thermoplastic ink.

Description

FIELD OF THE DISCLOSURE

This patent relates generally to decorative laminates and, more particularly, to decorative laminates including thermoplastic ink layers and related methods.

BACKGROUND

Vehicles (e.g., mass transit vehicles, tractor-trailers, personal automobiles, etc.), buildings and/or other structures (e.g., billboards) include surfaces that are visible to the people in the vehicles. Oftentimes, these surfaces include decorative images for aesthetic, informational and/or advertising purposes. For example, some interior surfaces of aircraft and/or other mass transit vehicles (e.g., buses, trains, ships, etc.) include decorative images that identify the mass transit provider (e.g., an airline carrier) and/or advertise for another entity. In some instances, the decorative images are formed by a decorative laminate that is coupled to a surface of the vehicle, building and/or other structure.

SUMMARY

In one example, an apparatus includes a reinforcing layer to provide a rigidity to a decorative laminate, thermoplastic ink applied to the reinforcing layer to form a decorative pattern of the decorative laminate, and a film layer coupled to the thermoplastic ink to form the decorative laminate. The film layer is to preserve the decorative pattern. The thermoplastic ink is solidified when the film layer is coupled to the thermoplastic ink.

In another example, a method includes applying thermoplastic ink to a reinforcing layer. The reinforcing layer is to provide a rigidity to a decorative laminate. The thermoplastic ink is to form a decorative pattern of the decorative laminate. The method includes solidifying the thermoplastic ink applied to the reinforcing layer and coupling a film layer to the thermoplastic ink to form the decorative laminate. The film layer is to preserve the decorative pattern of the decorative laminate.

In another example, an apparatus includes means for providing a rigidity to a decorative laminate and means for forming a decorative pattern applied to the means for providing a rigidity to form a decorative pattern of the decorative laminate. The means for forming a decorative pattern is to be solidified upon being applied to the means for providing a rigidity. The means for preserving a decorative pattern is coupled to the means for forming a decorative pattern to preserve the decorative pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an example aircraft in accordance with the teachings herein.

FIG. 2 depicts an example decorative laminate coupled to an interior surface of the aircraft ofFIG. 1 in accordance with the teachings herein.

FIG. 3A is a perspective view of an example decorative laminate in accordance with the teachings herein.

FIG. 3B is an exploded view of the decorative laminate ofFIG. 3A.

FIG. 4 is a partial cross-sectional view of the decorative laminate ofFIGS. 3A-3B without a textured surface.

FIG. 5 is another partial cross-sectional view of the decorative laminate ofFIGS. 3A-3B having a textured surface.

FIG. 6A is a perspective view of another example decorative laminate in accordance with the teachings herein.

FIG. 6B is an exploded view of the decorative laminate ofFIG. 7.

FIG. 7 is a flowchart representative of an example method to assemble the example decorative laminate ofFIG. 2, the example decorative laminate ofFIGS. 3A-5 and/or the example decorative laminate ofFIGS. 6A-6B in accordance with the teachings herein.

The figures are not to scale. Instead, to clarify multiple layers and regions, the thicknesses of the layers may be enlarged in the drawings. Wherever possible, the same reference numbers will be used throughout the drawing(s) and accompanying written description to refer to the same or like parts.

DETAILED DESCRIPTION

Surfaces in public spaces (e.g., billboards, building walls, vehicle panels, etc.) oftentimes include decorative images for aesthetic, informational, and/or advertising purposes. Some known aircraft and/or other mass transit vehicles (e.g., buses, trains, ships, etc.) often include decorative images (e.g., a decorative pattern, words, a logo, etc.) on their surfaces for aesthetic, informational and/or advertising purposes. For example, interior surfaces of mass transit vehicles include decorative images that identify the mass transit provider (e.g., an airline carrier) and/or advertise for another entity. In some examples, the decorative images are formed by a decorative laminate that is coupled to the interior surface of the vehicle.

Many known decorative laminates include a plurality of layers. For example, some known decorative laminates include a first film layer, an embossing resin layer, a second film layer, one or more ink layers, and a clear cap layer. In such examples, the embossing resin layer is disposed between the first and second film layers, and the ink layers are disposed between the second film layer and the clear cap layer. The first film layer provides a rigidity and/or strength to the decorative laminate, and the embossing resin layer bonds the layers of the decorative laminate together and enables a texture to be formed in the decorative laminate. The second film layer may be composed of an opaque material that acts as a primer and/or base layer for the decorative image of the decorative laminate. Further, the one or more ink layers are applied to the second film layer to form the decorative image. In such examples, the ink layers are composed of water-based ink that is applied to the second film layer via screen printing and is set in place by applying heat to evaporate the water of the water-based ink. Further, the cap layer is clear to enable viewing of the decorative images formed by the ink layers and the second film layer.

While such known decorative laminates enable a decorative image to be displayed on a surface of a structure (e.g., on an interior panel of an aircraft), the number, thicknesses and/or materials of the layers utilized to form the decorative laminate may add a significant amount of weight to a structure (e.g., an aircraft) on which it is installed. Further, such known decorative laminates may require a significant amount of time to be manufactured. For example, the amount of time to produce and/or assemble the plurality of layers (e.g., a plurality of film layers, an embossing resin layer, a plurality of ink layers, a clear cap layer) of the decorative laminates may be significant. Additionally or alternatively, it may take a significant amount of time to solidify (e.g., cure) the embossing resin that bonds the layers together and/or to dry the water-based ink via heat. Further, production of such known decorative laminates may result in a significant amount of waste. For example, some of the materials (e.g., embossing resin) utilized to form the decorative laminates may be unrecyclable, which prevents formed and/or partially formed decorative laminates from being recycled and, thus, produces waste. Additionally, known decorative laminates are formed utilizing precut segments of the layers. A significant amount of scrap material may result when cutting and/or forming the segments of the layers to be assembled, thereby resulting in waste associated with formation of the decorative laminates.

The example decorative laminates disclosed herein utilize thermoplastic ink (e.g., plastisol) that forms decorative images and/or patterns of the decorative laminates and solidifies to bond to an adjacent layer (e.g., a reinforcing layer) of the decorative laminates. That is, the thermoplastic ink of the examples disclosed herein forms the decorative pattern of the decorative laminate and bonds to the adjacent reinforcing layer. Thus, the layers of the example decorative laminates are assembled without use of a specialized embossing resin, thereby reducing a number of layers utilized to form the decorative laminates. By reducing the number of materials and/or layers utilized to form a decorative laminate, the examples disclosed herein reduce a weight of the decorative laminate.

Further, the examples disclosed herein substantially reduce manufacturing time and/or costs associated with assembling decorative laminates. For example, reducing the number of layers utilized to form the example decorative laminates reduces manufacturing time and/or costs. Additionally or alternatively, because the example decorative laminates do not utilize embossing resin to assemble the decorative laminates, manufacturing time and/or costs associated with curing the embossing resin is eliminated. In some examples, the decorative laminates disclosed herein are formed utilizing unsegmented rolls of material, thereby further reducing waste, manufacturing costs, and/or manufacturing time associated with segmenting and arranging segmented layers of the decorative laminates.

The example decorative laminates disclosed herein include a reinforcing layer that provides a rigidity to the decorative laminate and a thermoplastic ink that is applied to the reinforcing layers to form a decorative pattern of the decorative laminate. The thermoplastic ink may partially and/or completely cover the reinforcing layer. Further, the example decorative laminates include a film layer that is coupled to the thermoplastic ink to form the decorative laminate. The thermoplastic ink is partially or fully solidified when the film layer is coupled to the thermoplastic ink to prevent and/or deter the film layer from damaging and/or distorting the decorative pattern formed by the thermoplastic ink. In some examples, the decorative laminate has a textured surface. For example, the thermoplastic ink is textured to form the textured surface of the decorative laminate.

In some examples, the thermoplastic ink is composed of plastisol and the reinforcing layer is composed of woven fabric (e.g., polyester, fiberglass, Nomex®, Kevlar®, carbon fiber, etc.). For example, the woven fabric has a textured surface that increases, improves, enhances and/or otherwise enables bonding between the plastisol of the thermoplastic ink and the woven fabric of the reinforcing layer. Additionally or alternatively, the film layer may be composed of a clear thermoplastic film and an adhesive layer and/or a clear thermoplastic ink layer that is solidified.

In some examples, the thermoplastic ink includes a plurality of thermoplastic ink layers (e.g., a first thermoplastic ink layer, a second thermoplastic ink layer, etc.). For example, a first thermoplastic ink layer is applied to the reinforcing layer, a second thermoplastic ink layer is applied to the first thermoplastic ink layer, and the film layer couples to the second thermoplastic ink layer. In such examples, the decorative pattern is formed by a combination of decorative patterns of the respective thermoplastic ink layers. For example, the first thermoplastic ink layer may have a first pattern that covers the reinforcing layer and the second thermoplastic ink layer may have a second pattern that partially covers the first pattern to form the decorative pattern of the decorative laminate.

To form the example decorative laminates disclosed herein, the thermoplastic ink is applied to the reinforcing layer, the thermoplastic ink is solidified (e.g., cured) on the reinforcing layer, and the film layer is coupled to the solidified thermoplastic ink. To solidify (e.g., partially solidify) the thermoplastic ink, the thermoplastic ink is heated to at a temperature of at least about 150 degrees Fahrenheit. Further, to form the textured surface of the decorative laminate, a texture medium contacts the film layer, pressure is applied to the decorative laminate via the texture medium to form a texture in the decorative laminate, and the decorative laminate is heated to a temperature of at least about 300 degrees Fahrenheit to form the decorative laminate and/or set the texture in the decorative laminate.

In some examples, the decorative laminate is formed from a roll of the reinforcing layer. For example, the roll is unwound to enable the thermoplastic ink to be applied to the reinforcing layer and the film layer to be coupled to the thermoplastic ink, and the roll is subsequently rewound upon forming the decorative laminate. In examples in which the thermoplastic ink includes the first and second thermoplastic ink layers, the first thermoplastic ink layer is applied to the reinforcing layer upon the roll being unwound, the first thermoplastic ink layer is solidified, and the roll is rewound. Subsequently, the roll is again unwound, the second thermoplastic ink layer is applied to the first thermoplastic ink layer, the second thermoplastic ink layer is solidified, and the roll is again rewound. Additionally or alternatively, the roll may be unwound and subsequently rewound to enable the film layer to be coupled to the thermoplastic ink and/or to enable the textured surface to be formed in the decorative laminate.

As used herein, the terms “couple,” “coupled,” and “coupling” refer to a direct or indirect attachment of one object to another object (e.g., one layer to another layer). For example, a first object is directly attached and, thus, coupled to a second object if a surface of the first object contacts a surface of the second object without any other object disposed therebetween. A first object is indirectly attached and, thus, coupled to a second object if the first object does not directly contact the second object but, instead, is fixed to the second object via intermediate object(s) (e.g., layer(s)) that are positioned between the first and second objects. Further, as used herein, the terms “apply,” “applied,” and “application of” also refer to a direct or indirect attachment of one object to another object (e.g., one layer to another layer).

Turning to the figures,FIG. 1 illustrates anexample aircraft100 including wings102 (e.g., a right wing and a left wing) extending laterally outward from afuselage104. Each of thewings102 of the illustrated example supports anaircraft engine106 via apylon108. Apassenger compartment110 is disposed within thefuselage104 of the illustrated example.

FIG. 2 illustrates a portion of thepassenger compartment110 of theaircraft100 ofFIG. 1. Thepassenger compartment110 is defined, in part, by anupper wall202 and aside wall204. In the illustrated example, theupper wall202 is formed byupper wall panels206, and theside wall204 is formed byside wall panels208 in whichwindows210 are defined. As illustrated inFIG. 2, thepassenger compartment110 includesseats212 andoverhead bins214. For example, passengers are to be seated in theseats212 and carry-on luggage of the passengers and/or other materials are to be stowed in theoverhead bins214 during, before and/or after flight of theaircraft100.

As illustrated inFIG. 2, theoverhead bins214 includerespective doors216. In the illustrated example, each of thedoors216 of theoverhead bins214 is in a closed position such that luggage and/or other material disposed in theoverhead bins214 are retained by theoverhead bins214. Thedoors216 of theoverhead bins214 are formed byrespective panels218. For example, each of thepanels218 is composed of a honeycomb panel. A honeycomb panel is a composite structure in which a core layer is disposed between two opposing reinforcement layers. In some examples, the core layer is composed of lightweight material(s) and has a structure (e.g., the honeycomb pattern) that provides flexural strength (e.g., bending stiffness) to the honeycomb panel. For example, the core layer may be composed of a honeycomb core, a foam core and/or a combination thereof. Thus, the core layer provides flexural strength to the panel without adding a significant amount of weight. Further, in some examples, each of the reinforcement layers includes a fiber layer (e.g., fiberglass, graphite-cloth, synthetic fiber (e.g., Aramid fiber), natural fiber, (e.g., wood, flax, cellulose, jute, hemp, straw, switch grass, kenaf, cotton, coir, bamboo, etc.) pre-impregnated with resin that provides compression strength to the honeycomb panel.

Exampledecorative laminates220 in accordance with the teachings of this disclosure are coupled to thepanels218 of thedoors216. For example, each of thedecorative laminates220 is coupled to a respective one of thepanels218. In the illustrated examples, thedecorative laminates220 are positioned to form a decorative pattern or image222 (e.g., of a sky, mountains, and trees). For example, thedecorative image222 may be displayed in thepassenger compartment110 of the aircraft for aesthetic, informational and/or advertising purposes. While thedecorative laminates220 form thedecorative image222 in the illustrated example, thedecorative laminates220 may form more than one decorative image in other examples. For example, each of thedecorative laminates220 may form a decorative image independently of the otherdecorative laminates220. For example, a first decorative laminate may display a first decorative image that is unrelated to and/or identical to a second decorative image of a second decorative laminate, a third decorative image of a third decorative laminate, etc.

Additionally or alternatively, thedecorative laminates220 may be coupled to theupper wall panels206, theside wall panels208 and/or any other surface of thepassenger compartment110 of theaircraft100. For example, theupper wall panels206 and/or theside wall panels208 are composed of honeycomb panels and/or any other panel and/or material that enables thedecorative laminates220 to be applied to theupper wall panels206 and/or theside wall panels208. Further, the exampledecorative laminates220 may be coupled to other surfaces and/or panels of theaircraft100, other mass transit vehicles and/or any other structures.

FIGS. 3A-3B illustrate an exampledecorative laminate300 in accordance with the teachings of this disclosure. More specifically,FIG. 3A depicts thedecorative laminate300 when assembled, andFIG. 3B depicts an exploded view of thedecorative laminate300.

As illustrated inFIGS. 3A and 3B, thedecorative laminate300 includes a reinforcinglayer302, athermoplastic ink layer304, and a film orcap layer306. Thethermoplastic ink layer304 is coupled and/or applied to afirst surface308 of the reinforcinglayer302 and thefilm layer306 is coupled and/or applied to thethermoplastic ink layer304 opposite the reinforcinglayer302 such that thethermoplastic ink layer304 is disposed between the reinforcinglayer302 and thefilm layer306.

The reinforcinglayer302 of thedecorative laminate300 provides a rigidity and/or strength to thedecorative laminate300, for example, to enable thedecorative laminate300 to be securely coupled, fixed and/or adhered to a surface of a structure (e.g., one of thepanels218 ofFIG. 2). For example, the reinforcinglayer302 is composed of a woven or unwoven fabric such as polyester, fiberglass, Nomex®, Kevlar®, carbon fiber, and/or any other durable fabric. In other examples, the reinforcinglayer302 is composed of a rigid film. To enable the reinforcinglayer302 to withstand a manufacturing process of thedecorative laminate300 without deforming, the material of the reinforcing layer is resistant to contracting and/or expanding at substantially high temperatures (e.g., about between 150 and 320 degrees Fahrenheit). Further, in some examples, an adhesive layer is applied to asecond surface310 of the reinforcinglayer302 opposite thefirst surface308 to enable thedecorative laminate300 to be coupled and/or fixed to a surface of a structure (e.g., one of thepanels218 ofFIG. 2).

Thethermoplastic ink layer304 of the exampledecorative laminate300 includes a layer of thermoplastic ink that forms a decorative pattern orimage312 of thedecorative laminate300 and bonds to the reinforcinglayer302 to form thedecorative laminate300. For example, thethermoplastic ink layer304 includes color(s) and/or pattern(s) that form thedecorative image312. In the illustrated example, thethermoplastic ink layer304 is a solid layer of opaque ink covering the reinforcinglayer302 such that thedecorative image312 is a solid, opaque pattern. Further, the thermoplastic ink of thethermoplastic ink layer304 is, for example, a plastisol ink (i.e., a non-water-based ink) in which particles of polyvinyl chloride (PVC) are suspended in a liquid plasticizer that cures upon application of heat to the decorative laminate300 (e.g., when the ink is heated to a temperature of at least about 150 degrees Fahrenheit). In examples in which the reinforcinglayer302 is composed of fabric, the plastisol ink bonds to fibers of the fabric to securely bond the reinforcinglayer302 and thethermoplastic ink layer304 together. Thethermoplastic ink layer304 may be composed of fire-resistant material that, for example, enables thedecorative laminate300 to satisfy government agency regulations (e.g., of the Federal Aviation Agency) associated with installing laminates on aircraft.

Theexample film layer306 is a clear layer that is coupled to thethermoplastic ink layer304 opposite thefirst surface308 of the reinforcinglayer302 to prevent thethermoplastic ink layer304 from being damaged and/or to preserve thedecorative image312 formed by thethermoplastic ink layer304. Further, thefilm layer306 is clear, transparent and/or translucent to enable thedecorative image312 formed by thethermoplastic ink layer304 to be displayed when thedecorative laminate300 is formed. In some examples, thefilm layer306 includes a clear film (e.g., composed of polyvinyl fluoride (e.g., Tedlar®)) and an adhesive layer that is to couple to thethermoplastic ink layer304. In other examples, thefilm layer306 is a clear layer of solidified thermoplastic ink.

To form the exampledecorative laminate300, thethermoplastic ink layer304 is applied to thefirst surface308 of the reinforcinglayer302 and thefilm layer306 is applied to thethermoplastic ink layer304 opposite the reinforcinglayer302 such that thethermoplastic ink layer304 is disposed between the reinforcinglayer302 and thefilm layer306. For example, thethermoplastic ink layer304 is applied to the reinforcinglayer302 as a paste via a silkscreen printing process (e.g., utilizing a rotary silkscreen and/or a flatbed silkscreen). Further, thethermoplastic ink layer304 is solidified (e.g., cured) by applying heat and/or otherwise treating thethermoplastic ink layer304. For example, thethermoplastic ink layer304 is heated to a temperature of at least about 150 degrees Fahrenheit (e.g., via an oven) to partially solidify thethermoplastic ink layer304 and/or to a temperature of at least about 300 degrees Fahrenheit to fully solidify thethermoplastic ink layer304. Subsequently, thefilm layer306 is applied and/or coupled to thethermoplastic ink layer304 opposite the reinforcinglayer302. In some examples, another layer of thermoplastic ink is applied to thethermoplastic ink layer304 via a silkscreen printing process and/or a layer of non-thermoplastic ink (e.g., water-based ink) is applied to thethermoplastic ink layer304 via a silkscreen printing process and/or a digital printing process. To form thedecorative laminate300, thedecorative laminate300 is heated to a temperature of at least about 300 degrees Fahrenheit to bond thethermoplastic ink layer304 and the reinforcinglayer302 of thedecorative laminate300 together. In examples in which thefilm layer306 is a clear layer of thermoplastic ink, thedecorative laminate300 is heated to bond thethermoplastic ink layer304 and thefilm layer306 together.

Thus, thethermoplastic ink layer304 that forms thedecorative image312 of thedecorative laminate300 also bonds thethermoplastic ink layer304 and the reinforcinglayer302 together, thereby reducing a number of layers of thedecorative laminate300. For example, the reduced number of layers of thedecorative laminate300 reduces a weight of thedecorative laminate300. Further, the reduced number of layers reduces complexity in manufacturing thedecorative laminate300 and/or waste resulting from the manufacturing process, thereby reducing manufacturing time and/or costs associated with producing thedecorative laminate300.

In some examples, thedecorative laminate300 is formed on a roll of the reinforcinglayer302 to further reduce manufacturing time, manufacturing costs and/or waste. For example, to form thedecorative laminate300, the roll of the reinforcinglayer302 initially is unwound. While the roll is unwound, thethermoplastic ink layer304 is applied to and solidified (e.g., partially or fully) on the first surface of the reinforcinglayer302. The roll of the reinforcinglayer302 is then rewound. Subsequently, the roll again is unwound, thefilm layer306 is coupled to thethermoplastic ink layer304, and heat is applied to thedecorative laminate300 to bond thethermoplastic ink layer304 to the reinforcinglayer302 and/or thefilm layer306 of thedecorative laminate300. After thedecorative laminate300 is formed, the roll again may be rewound to enable an uncut roll of thedecorative laminate300 to be stored. By forming thedecorative laminate300 onto the roll without precutting segments of the reinforcinglayer302, thethermoplastic ink layer304 and/or thefilm layer306, manufacturing time, costs and/or waste associated with forming thedecorative laminate300 is reduced.

FIG. 4 is a partial cross-sectional view of the exampledecorative laminate300 and an example texture medium orhot press402 utilized to form an exampleouter surface404 of thedecorative laminate300 having a texture that is substantially flat. Thehot press402 is applied to thedecorative laminate300 to bond thethermoplastic ink layer304 to the reinforcinglayer302 and/or thefilm layer306 of thedecorative laminate300. That is, thehot press402 applies the heat and/or pressure to bond thethermoplastic ink layer304 to the reinforcinglayer302 and/or thefilm layer306. For example, thehot press402 applies a temperature of at least about 300 degrees (e.g., 320 degrees) to thedecorative laminate300 to bond thethermoplastic ink layer304 to the reinforcinglayer302 and/or thefilm layer306 and to fully solidify thethermoplastic ink layer304. As illustrated inFIG. 4, thehot press402 includes asurface406 that engages theouter surface404 of thedecorative laminate300 to enable thehot press402 to apply heat and/or pressure to thedecorative laminate300. In the illustrated example, thesurface406 of thehot press402 is flat so that theouter surface404 of thedecorative laminate300 is flat. Further, as illustrated inFIG. 4, thethermoplastic ink layer304 of thedecorative laminate300 has a thickness408 (e.g., a first thickness) that is greater than a thickness410 (e.g., a second thickness) of thefilm layer306.

FIG. 5 is a partial cross-sectional view of the exampledecorative laminate300 and another example texture medium orhot press502 utilized to form an exampleouter surface504 of thedecorative laminate300 that is embossed or textured. The texture or embossing of theouter surface504 and the color and/or patterns of thethermoplastic ink layer304 form the decorative image312 (FIGS. 3A-3B) of thedecorative laminate300. For example, thedecorative laminates220 ofFIG. 2 may be embossed to further illustrate the trees and the mountains of thedecorative image222 ofFIG. 2.

Returning toFIG. 5, thehot press502 has atextured surface506 that is to engage theouter surface504 of thedecorative laminate300. To form thedecorative laminate300, thetextured surface506 of thehot press502 engages theouter surface504 of thedecorative laminate300 and thehot press502 applies heat and/or pressure to bond thethermoplastic ink layer304 to the reinforcinglayer302 and/or thefilm layer306. Because thethermoplastic ink layer304 is malleable prior to being solidified by thehot press502, thethermoplastic ink layer304 becomes textured or embossed as thetextured surface506 of thehot press502 applies heat and/or pressure to thedecorative laminate300. As illustrated inFIG. 5, thetextured surface506 of thehot press502 produces atextured surface508 of thethermoplastic ink layer304. For example, prior to thehot press502 being applied to thedecorative laminate300, thethermoplastic ink layer304 has a uniform thickness substantially similar to thethickness408 ofFIG. 4 that enables thethermoplastic ink layer304 to become textured. After thehot press502 having thetextured surface506 engages thedecorative laminate300, thethermoplastic ink layer304 has anon-uniform thickness510 that is formed by and compliments thetextured surface506 of thehot press502. Because thethickness410 of thefilm layer306 remains substantially uniform, thetextured surface508 of thethermoplastic ink layer304 causes theouter surface504 of thedecorative laminate300 to be textured.

FIGS. 6A and 6B illustrate another exampledecorative laminate600 in accordance with the teachings disclosed herein. More specifically,FIG. 6A depicts thedecorative laminate600 when assembled, andFIG. 6B depicts an exploded view of thedecorative laminate600.

As illustrated inFIGS. 6A and 6B, thedecorative laminate600 includes the reinforcinglayer302,thermoplastic ink602, and thefilm layer306. In the illustrated example, thethermoplastic ink602 includes a firstthermoplastic ink layer604, a secondthermoplastic ink layer606, and a thirdthermoplastic ink layer608. The reinforcinglayer302 and thefilm layer306 ofFIGS. 6A and 6B are substantially similar or identical to those components having the same reference numbers inFIGS. 3A-5. Further, the firstthermoplastic ink layer604, the secondthermoplastic ink layer606, and the thirdthermoplastic ink layer608 ofFIGS. 6A and 6B are substantially similar or identical to thethermoplastic ink layer304 ofFIGS. 3A-5. Because the reinforcinglayer302, thethermoplastic ink layer304, and thefilm layer306 are described in detail in connection withFIGS. 3A-5, some characteristics of the reinforcinglayer302, thefilm layer306, the firstthermoplastic ink layer604, the secondthermoplastic ink layer606, and the thirdthermoplastic ink layer608 are not described in further detail below.

As illustrated inFIGS. 6A and 6B, the firstthermoplastic ink layer604, the secondthermoplastic ink layer606, and the thirdthermoplastic ink layer608 form a decorative pattern orimage610 of thedecorative laminate600. For example, each of the thermoplastic ink layers604,606,608 includes respective color(s) and/or pattern(s). The firstthermoplastic ink layer604 includes a first pattern orimage612, the secondthermoplastic ink layer606 includes a second pattern orimage614, and the thirdthermoplastic ink layer608 includes a third pattern orimage616 that form thedecorative image610. For example, the firstthermoplastic ink layer604 is a solid layer of opaque ink that is applied to the reinforcinglayer302 to cover the reinforcinglayer302. Further, the secondthermoplastic ink layer606 includes translucent and/or opaque ink that covers and/or partially covers the firstthermoplastic ink layer604, and the thirdthermoplastic ink layer608 includes translucent and/or opaque ink that covers and/or partially covers the firstthermoplastic ink layer604 and/or the secondthermoplastic ink layer606. For example, referring to thedecorative laminates220 ofFIG. 2, the firstthermoplastic ink layer604 forms the sky of thedecorative image222, the secondthermoplastic ink layer606 forms the mountains, and the thirdthermoplastic ink layer608 forms the trees.

To form the exampledecorative laminate600, the firstthermoplastic ink layer604 is applied to the reinforcinglayer302 and solidified upon being heated to a predetermined temperature. Subsequently, the secondthermoplastic ink layer606 is applied to the firstthermoplastic ink layer604 and solidified upon being heated to a predetermined temperature. Further, the thirdthermoplastic ink layer608 is applied to the secondthermoplastic ink layer606, the firstthermoplastic ink layer604 and/or the reinforcinglayer302 and solidified upon being heated to a predetermined temperature. In some examples, one or more of the thermoplastic ink layers604,606,608 may be fully solidified (e.g., fully cured) by heating the corresponding one or more of the thermoplastic ink layers604,606,608 to a temperature of at least about 300 degrees Fahrenheit (e.g., 320 degrees Fahrenheit) via an oven and/or other heating device. Additionally or alternatively, one or more of the thermoplastic ink layers604,606,608 are partially solidified by heating the corresponding one or more of the thermoplastic ink layers604,606,608 to a temperature of at least about 150 degrees Fahrenheit (e.g., 160 degrees Fahrenheit) via an oven and/or other heating device. In such examples, those of the thermoplastic ink layers604,606,608 that are partially solidified are subsequently fully solidified when the hot press (e.g., thehot press402 ofFIG. 4, thehot press502 ofFIG. 5) applies heat to thedecorative laminate600 to bond thelayers302,604,606,608 of thedecorative laminate600 together. By initially partially solidifying the thermoplastic ink layers604,606,608 via an oven and/or other heating device, manufacturing costs and/time associated with production of thedecorative laminate600 may be reduced.

In some examples, thedecorative laminate600 is formed on a roll of the reinforcinglayer302 to further reduce manufacturing time, manufacturing costs and/or waste. For example, to add the firstthermoplastic ink layer604 to thedecorative laminate600, the roll is unwound, the firstthermoplastic ink layer604 is applied to the unwound reinforcinglayer302, the firstthermoplastic ink layer604 is solidified (e.g., partially or fully), and the roll is rewound. Further, the second and third thermoplastic ink layers606,608 are added to thedecorative laminate600 in a manner similar to that for the firstthermoplastic ink layer604. After the thermoplastic ink layers604,606,608 are applied, thefilm layer306 is coupled to thethermoplastic ink602 and heat is applied to thedecorative laminate600 to bond thelayers302,604,606,608 of thedecorative laminate600 together.

In the illustrated example, thethermoplastic ink602 includes three layers of thermoplastic ink (e.g., the first, second, and third thermoplastic ink layers604,606,608). In other examples, thethermoplastic ink602 may include more (e.g., 4, 5, 6, etc.) or fewer (e.g., 1, 2) layers of thermoplastic ink. For example, thethermoplastic ink602 may have two layers including a first thermoplastic ink layer that is applied to the reinforcinglayer302 and a second thermoplastic ink layer that is applied to the first thermoplastic ink layer and/or the reinforcing layer and to which thefilm layer306 is applied.

FIG. 7 is a flowchart representative of anexample method700 to assemble an example decorative laminate in accordance with the teachings herein. Although theexample method700 is described with reference to the flowchart illustrated inFIG. 7, many other methods for assembling the decorative laminate may alternatively be used. For example, the order of execution of the blocks may be changed, and/or some of the blocks described changed, eliminated, and/or combined.

Themethod700 for assembling a decorative laminate is discussed in connection with thedecorative laminates220 ofFIG. 2, thedecorative laminate300 ofFIGS. 3A-5 and/or thedecorative laminate600 ofFIGS. 6A-6B. Further, because themethod700 may refer to thedecorative laminates220 ofFIG. 2, thedecorative laminate300 ofFIGS. 3A-5 and/or thedecorative laminate600 ofFIGS. 6A-6B, components identified inFIGS. 2-6B having functions substantially similar or identical to the functions of components described below will not be described in detail again. Instead, the same reference numbers will be used for like structures.

To form a decorative laminate (e.g., thedecorative laminates220 ofFIG. 2, thedecorative laminate300 ofFIGS. 3A-5, thedecorative laminate600 ofFIGS. 6A-6B), theexample method700 disclosed herein starts atblock702 by unwinding a roll of a reinforcing layer (e.g., a reinforcinglayer302 ofFIGS. 3A-6B). Atblock704, a first layer of thermoplastic ink (e.g., thethermoplastic ink layer304 ofFIGS. 3A-5, the firstthermoplastic ink layer604 ofFIGS. 6A-6B) is applied to the reinforcing layer. For example, the first layer of thermoplastic ink is applied to the reinforcing layer as a paste. In some examples, the thermoplastic ink is applied via a silkscreen printing process utilizing, for example, a rotary silkscreen and/or a flatbed silkscreen. Atblock706, the applied layer of thermoplastic ink is solidified (e.g., cured). In some examples, the layer of thermoplastic ink is fully solidified by heating the thermoplastic ink to a temperature of at least about 300 degrees Fahrenheit (e.g., to 320 degrees Fahrenheit). In other examples, the layer of thermoplastic ink is partially solidified (e.g., partially cured) by heating the thermoplastic ink for example, via an oven, to a temperature of about 150 degrees Fahrenheit (e.g., to 160 degrees Fahrenheit). Atblock708, the roll of the reinforcing layer is rewound.

Themethod700 includes determining whether there is another layer of thermoplastic ink (e.g., the secondthermoplastic ink layer606 ofFIGS. 6A-6B, the thirdthermoplastic ink layer608 ofFIGS. 6A-6B) to be applied to form the decorative laminate (block710). If there is another layer of thermoplastic ink to be applied, the other layer of thermoplastic ink is applied to the previously-applied layer(s) of thermoplastic ink and/or the reinforcing layer (block712). Further, blocks706,708 are repeated for the other layer of thermoplastic ink.Blocks706,708,710,712 are repeated until no other layers of thermoplastic ink are identified. Additionally or alternatively, a layer of non-thermoplastic ink (e.g., water-based ink) may be applied to the layer of thermoplastic ink solidified atblock706 via, for example, a silkscreen printing process and/or a digital printing process.

Atblock714, the roll of the reinforcing layer unto which the layer(s) of thermoplastic ink is applied is unwound. Atblock716, a film layer (e.g., thefilm layer306 ofFIGS. 3A-6B) is coupled to the layer(s) of thermoplastic ink to form the decorative laminate. In some examples, the film layer includes a clear, transparent and/or translucent film and an adhesive layer coupled to the film that is applied to the layer(s) of thermoplastic ink. In other examples, the film layer is a clear layer of thermoplastic ink that is solidified upon being applied to the layer(s) of thermoplastic ink.

Atblock718, a texture medium (e.g., thehot press502 ofFIG. 5) is applied to the decorative laminate. For example, a textured surface (e.g., thetextured surface506 ofFIG. 5) of a texture medium (e.g., thehot press502 ofFIG. 5) engages an outer surface (e.g., theouter surface504 ofFIG. 5) of the decorative laminate to form a texture (e.g., an embossment) in the decorative laminate.

Atblock720, heat and/or pressure is applied to the decorative laminate to set the decorative laminate. For example, the heat and/or pressure are applied to cure the layer(s) of thermoplastic ink to bond the layer(s) of the decorative laminate together. In some examples, the decorative laminate is heated to a temperature of at least about 300 degrees Fahrenheit to set the decorative laminate. In examples in which the texture is to be formed in the decorative laminate, heat may be applied to the decorative laminate via the texture medium having the textured surface. In examples in which the texture is not to be formed in the decorative laminate, heat may be applied to the decorative laminate via a texture medium (e.g., thehot press402 ofFIG. 402) having a substantially flat surface (e.g., thesurface406 ofFIG. 4) that engages the decorative laminate. Atblock722, the roll of the decorative laminate is rewound to enable the uncut roll of decorative laminate to be stored.

Although certain example apparatus and methods have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the amended claims either literally or under doctrine of equivalents.

Claims (20)

What is claimed is:

1. A method comprising:

applying thermoplastic ink to a reinforcing layer, the reinforcing layer to provide a rigidity to a decorative laminate, the thermoplastic ink to form a decorative pattern of the decorative laminate;

applying heat, via an oven, to partially solidify the thermoplastic ink applied to the reinforcing layer;

coupling a film layer to the thermoplastic ink to form the decorative laminate, the film layer to preserve the decorative pattern of the decorative laminate, the thermoplastic ink to remain partially solidified during coupling of the film layer to the thermoplastic ink;

contacting a heated press to the film layer;

embossing, via the heated press, the decorative laminate to define an embossed shape of the decorative laminate, wherein the decorative laminate is to be heated to a temperature of at least about 300 degrees Fahrenheit by the heated press during the embossing to set the embossed shape of the decorative laminate; and

fully solidifying, via the heated press, the partially solidified thermoplastic ink during the embossing of the decorate laminate.

2. The method ofclaim 1, wherein applying the thermoplastic ink to the reinforcing layer includes applying the thermoplastic ink to a roll of the reinforcing layer that is unwound.

3. The method ofclaim 2, wherein the roll is unwound prior applying the thermoplastic ink to the reinforcing layer and is rewound upon forming the decorative laminate.

4. The method ofclaim 1, wherein applying the thermoplastic ink to the reinforcing layer includes applying a first thermoplastic ink layer to the reinforcing layer and applying a second thermoplastic ink layer to the first thermoplastic ink layer.

5. The method ofclaim 4, further including:

winding the reinforcing layer and the first thermoplastic ink layer into a roll upon partially solidifying the first thermoplastic ink layer on the reinforcing layer; and

unwinding the roll of the reinforcing layer and the first thermoplastic ink layer to enable the second thermoplastic ink layer to be applied to the first thermoplastic ink layer.

6. The method ofclaim 1, wherein coupling the film layer includes applying a clear thermoplastic ink layer to the thermoplastic ink applied to the reinforcing layer.

7. The method ofclaim 1, wherein the reinforcing layer includes a fiber layer.

8. The method ofclaim 7, wherein the fiber layer includes a synthetic fiber.

9. The method ofclaim 7, wherein the fiber layer includes a natural fiber.

10. The method ofclaim 1, wherein the heated press is to cause the thermoplastic ink to have a non-uniform thickness.

11. A method of forming a decorative laminate, the method comprising:

providing a reinforcing layer having a rigid film that defines a first surface and a second surface opposite the first surface;

forming a decorative pattern of the decorative laminate by applying a thermoplastic ink layer to the first surface of the reinforcing layer;

applying heat, via an oven, to partially solidify the thermoplastic ink layer applied to the first surface;

coupling a film layer to the thermoplastic ink layer, the film layer to protect the decorative pattern formed by the thermoplastic ink layer, the thermoplastic ink layer to remain partially solidified during coupling of the film layer to the thermoplastic ink layer;

contacting a heated press to the film layer;

embossing, via the heated press, the decorative laminate-to define an embossed shape of the decorative laminate, wherein the decorative laminate is to be heated by the heated press to a temperature of at least about 300 degrees Fahrenheit to set the embossed shape of the decorative laminate; and

fully solidifying, via the heated press, the partially solidified thermoplastic ink layer during the embossing of the decorate laminate.

12. The method ofclaim 11, wherein the providing of the reinforcing layer includes forming the reinforcing layer from woven or unwoven fabric including at least one of polyester, fiberglass, or carbon fiber.

13. The method ofclaim 12, wherein the applying the thermoplastic ink layer includes applying a layer of thermoplastic ink to the first surface of the reinforcing layer.

14. The method ofclaim 11, wherein the applying the thermoplastic ink layer includes applying a first thermoplastic ink layer on the reinforcement layer in a first pattern and applying a second thermoplastic ink layer on the first thermoplastic ink layer in a second pattern, the first pattern and the second pattern forming the decorative pattern of the decorative laminate.

15. The method ofclaim 11, further including bonding the thermoplastic ink layer to the reinforcement layer.

16. The method ofclaim 11, wherein coupling the film layer includes applying a clear thermoplastic ink layer to the thermoplastic ink applied to the reinforcing layer.

17. A method of forming a decorative laminate, the method comprising:

unwinding a roll of a reinforcing layer;

applying a thermoplastic ink layer to an unwound portion of the reinforcing layer to form a decorative image;

applying heat, via an oven, to partially solidify the thermoplastic ink layer;

coupling a film layer to the thermoplastic ink layer, the thermoplastic ink layer to remain partially solidified during coupling of the film layer to the thermoplastic ink layer;

contacting a heated press to the film layer;

embossing, via the heated press, the decorative laminate to define an embossed shape of the decorative laminate while heating the decorative laminate, via the heated press, to a temperature of at least about 300 degrees Fahrenheit to set the embossed shape of the decorative laminate; and

fully solidifying, via the heated press, the partially solidified thermoplastic ink layer during the embossing of the decorate laminate.

18. The method ofclaim 17, wherein the applying of the thermoplastic ink layer includes applying a thermoplastic ink to the reinforcing layer via a silkscreen printing process.

19. The method ofclaim 17, wherein applying the thermoplastic ink layer includes applying a first thermoplastic ink layer to the reinforcing layer, and applying a second thermoplastic ink layer to the first thermoplastic ink layer.

20. The method ofclaim 17, further including applying a non-thermoplastic ink layer to the thermoplastic ink layer.

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